KnowHow 2-2012 English by Pentair

2012 volume 15 issue 2 K now H ow

by penta ir

is published

Focus on Efficiency

For a German Mid-size Brewery

Water & Environmental Systems

Kenia Coal Seam Gas Operation Receives Pipeline

The Waste Challenge Solution for Industries

Welcome to the new Pentair! â&#x20AC;&#x153;Newâ&#x20AC;?, because we have recently finalized our merger with Tycoâ&#x20AC;&#x2122;s worldwide Flow Control business. Our newly combined company brings together our highly complementary businesses, creating a global leader providing water and fluid solutions, valves and controls, equipment protection and thermal management products.

Now, with 30,000 employees and more than 100 manufacturing facilities in over 30 countries, we have significantly increased our global presence, providing a broader scope of products, solutions and applications around the world. From pools, pure water systems, residential water filtration, flood control pumps

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and electrical/electronic enclosures to advanced valves, thermal management and piping systems for major water infrastructure, Pentair is ready to provide comprehensive solutions for your needs. No matter where you are in the world, you are never far from a Pentair product. In addition to providing systems and solutions, our customer service continues to be unwavering. With the combined company, Pentair has expanded service capabilities encompassing over 90 service centers and 1,100 service technicians worldwide. We are excited about the future and look forward to working with you to showcase our expanded portfolio of technologies and solutions. In this issue of KnowHow, we have highlighted a variety of products and applications, providing solutions ranging from increasing dairy production to lowering discharge costs in wastewater streams to protecting critical instrumentation and control systems in hazardous environmental locations. I hope that you enjoy this issue. As our company continues to grow and develop, we are committed to bringing you news on the latest developments across Pentair.

Michael V. Schrock President and Chief Operating Officer Pentair Ltd. www.pentair.com

flow technologies

Flow Technologies Debuts

New Global Offering

Pentair Flow Technologies debuted a powerful, new branded product line Fairbanks NijhuisTM, at the Water Environment Federation’s Annual Technical Exhibition (WEFTEC) in September 2012. The new line is actually the joining of two leading water solutions brands: Fairbanks Morse® and Nijhuis.

MIKE BOTHWELL

Fairbanks Morse, headquartered in Kansas City, Kansas (USA), has provided custom pump solutions to municipal and industrial customers since 1885. Nijhuis, headquartered in Winterswijk, the Netherlands, has been one of the leading worldwide providers of custom-engineered water and fire protection solutions since 1904. These venerable brands—with two centuries of combined expertise—have come together to form a powerhouse in infrastructure and industrial markets. This move accomplishes several objectives. It allows Pentair to better serve global customers with locations across North America, Europe, Asia, and Latin America. The new product line provides a true “systems approach” to custom-engineered

solutions–everything from pumps, to controls, to valves, to predictive maintenance. This approach allows customers to use a single source for new installations, avoiding the cost and logistics of managing multiple vendors. WEFTEC was an ideal event to debut Fairbanks Nijhuis. Recognized as the world’s largest annual water quality exhibition, WEFTEC’s massive show floor provided unparalleled access to the field’s most cutting-edge technologies and services. Nearly 20,000 attendees had the opportunity to learn how the new Fairbanks Nijhuis offers complete systems solutions, engineering competencies and extensive distribution coverage. Pentair experts staffed the booth and explained the new line’s many benefits. More information on Fairbanks Nijhuis, including industries, applications and product types, can be found at our new website www.FairbanksNijhuis.com.

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process technologies

The German brewery Ganter wanted to reduce overcapacity while focusing on quality. This strategy has been implemented in a newly designed brewery with a highly efficient cold block and the first-ever installation of Pentair’s BMF-18 Compact beer membrane filtration system. The increase in efficiency is clearly reflected in the consumption figures. by

RIK SCHUURMAN & HELMUT WITTMANN

Focus on Efficiency for a German Mid-size Brewery

The yeast management includes pure culture tanks for bottom-fermenting and top-fermenting yeast, including pumping units and aeration units, and a yeast tank.

Ganter’s Managing Director, Detlef Frankenberger wanted to reduce overcapacity and increase efficiency at its old 33,000 square meter master brewery. The company redesigned the brewery. The bottling system, which was too large, has been taken out of service and that process is now outsourced. A new 700 square meter hall was built and Pentair Südmo installed a compact and highly automated cold block that includes a keg filling system. Over the past four years, Ganter modernized and became automated with ProLeit’s Brewmaxx system. This process control system was selected for the cold block to have a continuous and uniform solution. Südmo conducted a brewing process engineering project in a turnkey format, holding the responsibility for engineering, assembly, automation and commissioning of the cold block. The brewhouse project included the new installation of sixteen cylindro-conical tanks (CCTs) and five pressure tanks, each holding 600 hectoliters, a Pentair Haffmans CCR Carbonator and a glycol

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The BMF-18 Compact from Pentair is a turnkey solution for breweries that have an annual output of up to 1,500,000 hl. All necessary components are mounted on a stainless steel frame.

chiller. Other components included the reconstruction and integration of existing dealcoholization systems and

flash pasteurizers as well as the yeast storage cellar. The yeast management includes pure culture tanks for

bottom-fermenting and top-fermenting yeast with pumping and aeration units, and a yeast tank. Also, new CIP systems in the cold block ensure a strict separation of filtered and unfiltered beer. “The entire cold block works almost completely automatically,” summarized Frankenberger. “We only have to lay out the path every now and then and then press the start button. The work done so far has been great.”

First worldwide BMF-18 Compact Installation

During the first stage of the project, the Ganter Brewery selected a diatomaceous earth filter for the cold section. “We even bought a new one as the old one was far too big,” Frankenberger explained. “Then the BMF-18 Compact concept was presented to us. This membrane filter was developed especially for small and medium-sized breweries and is therefore particularly attractive in terms of investment costs. As a result,

we sold our new diatomaceous earth filter after only eleven months.” Pentair’s BMF-18 Compact offers breweries a turnkey solution with an annual output of up to 1,500,000 hectoliter. The compact system design features a stainless steel frame containing all necessary components including the membrane module block, the unfiltered beer tank, the controller, the CIP system, and the security filter. The system is completely piped, automated and tested before being delivered to the customer. To comply with German purity laws for beer, the filter produces 100 hectoliters per hour with a service life of 1,000 to 1,500 hectoliters before cleaning. Switching between filtration and cleaning is accomplished by simply turning both swing bends. All other process steps, including filtration, rinsing or cleaning are fully automated. In April 2012, Ganter installed the BMF-18 Compact in the new cold

block and converted the filtration system in a week. “Replacing a new diatomaceous earth filter is certainly unusual,” Frankenberger said. “But we had redone everything and were at the forefront of technological developments. Quite simply, diatomaceous earth is an old system, whereas membrane filtration is the future.” The experience of commissioning the BMF has been overwhelmingly positive. “The membrane filter works brilliantly,” emphasized Frankenberger. “The filter is designed to produce 1,000 hectoliters per run. Even in such a short period after commissioning, we have already been able to achieve runs with 1,200 hectoliters and have successfully filtered wheat beer and bock beer as well.”

Efficiency Reflected in Consumption Figures

The new Ganter Brewery has been in operation for approximately a year and a half. One thing is clear: the modern and compact brewery is extremely efficient. Currently, three employees per shift look after the entire production process, including the brewhouse, fermentation, storage and filtration cellars, as well as the keg filling system. This increase in efficiency is reflected in the consumption figures. Compared to the old brewery, the new Ganter Brewery consumes 30 percent less fresh water and 52 percent less energy (an annual savings of 500,000 Euros). Maintenance costs are 70 percent lower while producing 23 percent less wastewater. And these savings do not take into account membrane filtration.

Detlef Frankenberger, Managing Director at Ganter

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va lv e s

controls

Fast Freeze for Shetland Fish Processors Europeâ&#x20AC;&#x2122;s largest fresh fish blast freeze refrigeration plant employs Winn Hi-Seal valves from Pentair to ensure there is minimum pressure drop in the vital flow of ammonia refrigerant. by

Rising to the Challenge

RICHARD MORRIS

Ten rapid freeze chambers were installed by Star Refrigeration as part of a ÂŁ10 million facility created by Shetland Catch to expand its dockside processing plant in Lerwick, on Shetland Islands, Scotland. The pelagic fish factory, perfectly situated in the middle of the North Atlantic fishing grounds, was designed to handle fresh herring and mackerel, freezing up to 860 metric tonnes a day. The fish is blast frozen within 18 hours to protect quality, and is then transferred into a 12,000 mt capacity cold store

until worldwide dispatch. The ammonia refrigerant for each of the blast freezers flows through 200mm pipework and is controlled by the Winn Hi-Seal butterfly valves. These valves feature stainless steel bodies, ENP-coated stainless steel discs and Inconel seats. Metal-seated valves were selected rather than soft-seated to increase durability in the arduous conditions. The Winn valves are operated by Keystone electric actuators, which are fitted with internal heaters to prevent condensation and consequent corrosion, affecting the actuator performance.

In arid San Diego County in Southern California, water is a carefully managed resource. More than 90 percent of the water needed in the region must be imported from hundreds of miles away. That is a big risk in this earthquake-prone region. by

MIKE CONNOR

Just twenty-five miles north of San Diego, behind the San Vicente Dam, a man-made lake was created as an emergency reservoir, and a wonderful recreational facility. As the region grew, however, a problem emerged: would there be enough water to cope in a true emergency? The San Diego County Water Authority felt it had to take action. The existing

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wat e r

e n v i r o n m e n ta l s y s t e m s

Pentair’s Wacol, Australia, steel manufacturing facility has recently completed the supply of pipe and fittings for the 20km Kenya water treatment plant to Chinchilla pipeline 250km west of Brisbane, Queensland. by

220 ft. (67m) high dam held about 90,000 acre-feet of water. Raising the dam by 117 ft. (35.66m) would more than double its capacity. A new 11-mile pipeline and pumping facility would ensure that an uninterrupted water supply could reach the Water Authority’s second aqueduct. The construction contractor turned to Pentair’s Valves & Controls business for key components, including: one 108” Vanessa valve with Biffi actuation; a 90” and a 66” Vanessa valve, and four 60” Rovalve knife gate valves. Work on raising the dam height is well underway. In order to bond new concrete to the existing structure, crews had to scrape off one to two feet from the top of the dam. New excavations and foundations needed to be built into the hillside to support the extended dam walls. The dam raise should be complete in late 2012. The Water Authority keeps the surrounding community informed about progress through its website and newsletters. When all is complete, county residents will also enjoy a new marina and lakeside park. Most importantly, however, in the event of an emergency, they can be confident of a clean water supply.

DAVID BRADY

Kenya coal seam gas operation receives pipeline Pentair was awarded the contract to supply the high-pressure pipeline to transport water from QGC’s coal seam gas operations at Kenya to Chinchilla Weir. The water, collected as a byproduct of the coal seam gas extraction process, is treated using reverse osmosis technology at Kenya and stored on site. The pipeline is then required to transport the treated water to the weir to return excess flows to the water cycle. According to the water infrastructure developer, the pipeline will provide water that benefits the agriculture community. The water will also be made available to

supplement the Chinchilla town water supply. The project involves supplying approximately 16km of 1016mm of the company’s specially-designed and patented steel cement lined SINTAKOTE pipe and 4km of 813mm Steel Cement Lined SINTAKOTE pipe and associated fittings. The pipes featured our unique SINTALOCK jointing system which provides the structural benefits of a welded joint in the highly expansive soils, eliminating the need to enter the pipes for internal welding or lining reinstatement. Our patented technology resulted in increased safety for the customer as well as a drastically reduced construction time.

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p er qo uc i pem se s ntte c ph rn ot o el c o tgiioen s

Engineers design with confidence

harsh Environment solutions by

DOUG FRANZ

The harsh environments in the oil and gas industries necessitate a broad range of enclosure solutions to protect critical instrumentation and control systems. Whether it is saltwater in an offshore oil platform, sub-zero weather on a natural gas pipeline or corrosive chemicals in a gasoline refinery, Hoffman™ brand enclosures must withstand the elements and protect the vital controls. Since 1953, customers have admired Hoffman enclosures for their superior performance. The product offerings have expanded to meet the oil and gas market’s needs, as influenced by several environmental factors. For example, airborne chemicals determine the best enclosure material, but also the best gasket material for long-term protection against dust and water ingress. In the case of the offshore platform, an enclosure constructed of 316 Stainless Steel with a polyurethane or silicone foam gasket performs best against sodium

chloride (salt). For a natural gas pipeline, an aluminum enclosure with polyurethane or silicone foam gasket material offers a lighter weight material and solid protection against frigid outdoor environments. Refinery applications involve a wide variety of corrosive chemicals that require engineers to match the specific chemical to the enclosure materials. In acidic environments, plastic enclosures such as ABS and polycarbonate along with glass-reinforced polyester (fiberglass) perform extremely well, whereas in heavy solvent environments 304 and 316 Stainless steel provide superior protection.

inside the enclosure never exceeds the auto-ignition temperature of the hazardous gas/dust present. Pentair’s new Hoffman brand Zonex enclosures are certified to the IEC Ex e, increased safety protection method, for Zones 1 and 2 (gas) and Zones 21 and 22 (dust environments). In addition to the IEC Ex certification, Zonex enclosures are certified to the European ATEX standard, the American AEx requirements, and the Australia/New Zealand ANZEx scheme. These enclosures utilize 316 Stainless Steel for superior corrosion protection and are available with two different gasket options depending on the environment. Polyurethane gaskets offer protection in milder temperature ranges whereas high temp silicone gaskets protect in more extreme temperatures. With customers’ project timelines becoming more and more critical, Pentair Equipment Protection offers Zonex enclosures with industry-leading delivery times that far surpass the closest competitor allowing engineers to design and deploy with confidence.

In 2012, Pentair launched an exciting new offering that extends the Hoffman brand even further. The new Zonex™ Stainless Steel junction box enclosure is certified for use in hazardous location environments, as defined by the IEC 60079 standard. In many hazardous location applications, process control systems require a junction box to connect field device wiring (sensors, transmitters, gauges) to the controller input/output modules. Under the increased protection method, these connection points must be designed so that the heat produced

Hoffman Stainless Steel enclosures protect electrical control equipment in a variety of upstream and downstream applications

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wat e r p u r i f i c at i o n

Pentair Water Purification’s core values support product design integrity and exceptional durability, because they catalyze growth. In a competitive economy, customers demand more from their preferred manufacturers— and Pentair delivers. In May of 2012, Pentair announced the newest, most user-friendly addition to its valve platform: the 5800 Fleck® valve.

The Next Generation Valve Platform:

The Fleck® 5800

HEATHER KOEHN

The design of the 5800 focused on creating a water softener valve that offers increased flexibility during installation and maintenance. The innovative design provides a higher flow rate, higher speed DC drive motor, and up and down flow versatility. The backlit display allows work in dark installations. Most notably, the 5800 includes a single piece seal and spacer cartridge, 12 hours of time clock power loss protection and a good (LXT), better (SXT), best (XTR) option for OEMs and Dealers to choose from. The Water Purification business places great emphasis on designing and manufacturing next generation products that exceed OEM and Dealer expectations. In an economic environment that requires businesses to minimize installation time and maximize customer touch points, the 5800’s design exceeds our customers’ expectations, continuing Fleck® valves’ proud legacy.

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In 2010, Pentair Südmo supplied Arla Foods with more than 100 valves as part of the Hollandtown Dairy expansion and improvement. The project included replacing antiquated valving on cheese vats, which increased daily production time by two hours each day and daily raw milk use by up to 100,000 additional pounds. The success of this project led Arla to install approximately 200 more Südmo valves in 2011 as expansion at the plant continued. 10

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Südmo Valves EQUIP

Arla’s Hollandtown Dairy

Mary George

Arla Foods, a global dairy company and a co-operative owned by Danish, Swedish and German dairy farmers, brought its Havarti production to the United States when it purchased the White Clover Dairy in 2006. Located in Hollandtown, Wisconsin, this dairy dates back to 1897 and has a long history of cheese making, including Edam and Gouda. Today, the Hollandtown Dairy is the largest U.S. producer of Havarti, making 27 million pounds annually, and crafts award-winning Gouda and Edam cheese made according to old world recipes and methods. Arla Foods is driven by its commitment to following a “Closer to Nature” philosophy that extends from the cow to the consumer. “We have our own farmers and only use milk that is hormone free,” said Henrik Jessen, Site Director at Hollandtown. “Throughout the production process we focus on food safety and quality as a first priority.” By partnering with Südmo as its valve provider, Arla Foods is able to assure both safety and quality at the Hollandtown

plant, plus the lean, simple set-up of the valves increases the production efficiency. The benefits from the upgrades at the plant that included Südmo’s single seat and mix proof valves, and control units are measurable. “The cheese vats can now be operated by one person per shift, where in the past it took two,” said Ted Vande Yacht, Engineering/Maintenance Manager at Hollandtown. “We can now wash more than one circuit at a time so cleaning is faster, there is less waste of water and cleaning solutions, and the process is automated instead of manual.”

Milk In, Cheese Out

At Hollandtown, Südmo valves are used throughout the plant, from raw milk

Hollandtown Dairy Fast Facts

Local Employees 190 Daily raw milk use – 1.3 million pounds Daily cheese production up to 100,000 pounds Cheeses produced – Havarti, Gouda, Edam, Fontana, Munster and Farmers

process technologies

receiving to curd discharge. Hollandtown gained the greatest efficiency when Südmo’s 365it PMO Mix Proof valve technology replaced the swing bend systems that were previously used on the cheese vats. By using mix proof valves, one valve replaces three valves while providing many process benefits. The 365it PMO Mix Proof Valve eliminates waiting time for clean-in-place (CIP) and allows fully automated processing and CIP of milk fill. Using a 365it Mix Proof Valve coupled to the milk fill line and vat, Hollandtown can fill vats as needed, and the milk lines can CIP regardless of vat processing. “Our mix proof technology allows for continuous cleaning and processing at the same time, which meets Arla’s needs,” said Jim Banks, Director of Sales for Südmo in North America. “Most of the valves used by Arla include control units that allow for the control and feedback position detection of the pneumatic process valves.” Curd discharge is a critical component of cheese processing. When curd is

transferred through pipework, it must be handled gently to ensure minimal shear to the fragile curd. With conventional valving, cheese vats require large and complicated valving arrangements. Now, safe separation of curd and CIP is accomplished with one compact valve arrangement. “We now have fewer valves to maintain and they are easier to work with,” Vande Yacht said. “Also, Südmo provides good support, training and education.”

365it Complete PMO Mix Proof Valve Fast Facts •F irst PMO mix proof valve with less than a full port leakage chamber to meet 3-A 85-02 standards

• EHEDG certified for cleanability • I ntelliTop® 2.0 Control Unit

- Provides required feedback to meet PMO - Fast and easy setup - IP65, IP67, IP69 protection classes

Arla’s Hollandtown Dairy was the first cheese plant to install Südmo’s new 365it Complete PMO Curd Outlet Valve. This valve meets the latest requirements for having a leakage outlet less than 100 percent compared to its pipe size and approved for seat lift with product on one side and CIP on the other side.

Set for Growth

Arla’s Hollandtown Dairy is growing and Südmo valves make that process easier. “Before it would take six weeks to train a new employee to operate a system and now because of the automation training time is cut in half,” said Mark Hinderman, Production Manager at Hollandtown.

Below Südmo’s valves are used for routing CIP of the pressing system

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flow technologies

Jung Pumpen’s “PumpSizer” App:

The latest “PumpSizer” app update from Jung Pumpen makes it easier than ever to select the perfect submersible drainage pump or wastewater lifting station to meet your specific building conditions.

Planning Tool for Plumbers

ANDREAS KÄMPF

The “PumpSizer” app for iPhones and Androids calculates hydraulic parameters for draining wastewater with pumps. Plumbers and other professionals can plan their work by simply entering the hydraulic data, the media to be pumped and the intended installation site. Which pump do I need for my purpose and how powerful does it need to be? These are the kind of questions plumbers ask when wastewater needs to be drained from toilets, showers or bathtubs. Jung Pumpen, the premium manufacturer from Steinhagen, Germany, developed this latest app to provide a quick and accurate answers to these questions. After entering only a few pieces of information, the “PumpSizer” app displays the submersible drainage pump that will meet the building conditions specified. The extensive aids when entering data mean that all parameters are quickly and easily calculated. The user selects the key data for the building project from a list of suggested buildings, types of water and installation sites and in this way defines the application profile for the pump. Next, the user determines the expected volume of wastewater to be pumped with the aid of a list of common objects to be drained such as showers, toilets, washbasins, washing machines, etc. The app prompts the user to enter the length, diameter and delivery head of the pipe system. If the data conflicts, the app alerts the user. With consistent data, the app calculates the operating points, computes and graphically displays the

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By entering only a few pieces of information, the new “PumpSizer” app enables you to find a suitable pump.

pump’s characteristic curve and, finally, recommends possible pumps.

Other useful features

The application also contains vivid 3D animations on building drainage, numerous product and pipe tables, as well as a database for quickly finding specific pumps. The app presents facts about back-flow protection and underfloor pipework clearly and concisely. In addition, a product substitution table gives recommendations if other brand pumps are already in use and need to be replaced. The app provides contact details for Pentair Jung Pumpen’s customer service numbers, as well as a telephone hotline for emergencies on the weekends, providing easy access to the manufacturer’s extensive service features. The “PumpSizer” app is available in German, English and Italian. It is not necessary to have an online connection to use the software, but this increases the range of information available in some sections. The latest posts on Jung Pumpen’s Facebook page, for instance, can be accessed directly within the application. The new “PumpSizer” app from JungPumpen enables plumbers and other professionals to get the job done quickly and accurately.

After calculating the hydraulic parameters, the app reads out the operating points and the pump’s characteristic curve and also displays them graphically.

Suitable submersible drainage pumps recommended by the app for the parameters specified are shown in tables.

flow technologies

Media coverage of the “Flutbox” emergency flood kit has generated substantial interest in this product, particularly from end-users. To fuel this interest, Pentair Jung Pumpen has built a “Flutbox” website for potential end-user customers, Flutbox.com.

ANDREAS KÄMPF

Jung Pumpen “Flutbox” Emergency Flood Relief

Jung Pumpen also provides extensive information for potential buyers and promotional and incentive activities for trade professionals on its new microsite www.flutbox.com.

Is rainwater collecting outside on the street and already starting to seep into your cellar or basement? Now is the time to spring into action and rescue whatever can be salvaged! Jung Pumpen’s “Flutbox” emergency kit provides all the materials to remove water from your cellar or basement without stress. Just place the plastic box with its integrated pump on the cellar floor, screw on the fire hose with the attached Storz coupling and connect it to the electricity. Immediately the “Flutbox” will be pumping out 9

cubic metres of water per hour. This is equivalent to a staggering 50 or so bathfuls. After seeing it on the inventions programme, “Einfach Genial,” broadcasted on MDR, NDR, RBB and Einsplus German TV channels, many of those affected by rainwater seepage lost no time in contacting Jung Pumpen to purchase the “Flutbox.” Jung Pumpen’s three-tiered marketing system (wholesaler/plumber/end user) does not involve selling directly to the

end-user. Jung Pumpen created a new informative website, www.flutbox.com, to give potential customers important information, useful animated clips and the TV program feature. Customers who want to purchase the “Flutbox” can simply enter their postcode to find the nearest dealer. Plumbers who register with this site can receive marketing aids and advertising materials, such as display posters, promotional leaflets for potential buyers, as well as a radio commercial.

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wat e r p u r i f i c at i o n

Pentair adds Hybrid DI to Commercial Portfolio Pentair Water Purification welcomes the Hybrid DI to its portfolio of innovative, industry-changing technologies. While Pentair offers a residential system, it has turned its focus to commercial applications to partner with the industry in reducing energy costs and discharging less wastewater. by

ALISHA JAVA

The Hybrid DI system shows potential in several pre-treatment commercial applications that currently employ a combination of ion-exchange, reverse osmosis and deionization systems. The system’s flexibility and efficient water use provide more than one solution for cost savings and increased productivity. Commercial application opportunities abound – from car washes to healthcare. In car wash applications, the Hybrid DI is more water and energy efficient than traditional reverse osmosis treatment methods, while also offering the added benefit of spot prevention. Spotting during a car wash occurs due to dissolved minerals and ions produced from the softening process of water; the

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RO treatment from the Hybrid DI reduces spots significantly. In these applications, the Hybrid DI offers an attractive alternative to the traditional spot-free rinse. The Hybrid DI system’s flexibility and efficient water use will ultimately provide more than one solution for cost savings and increased productivity results. The system can also be useful in commercial boiler rooms, general distribution to apartments, assisted living homes, high towers and other installations where community living would benefit from a salt-free alternative to water softening and drinking water filtration, from the same system. Pentair Water Purification is excited to introduce the industry’s first Hybrid DI commercial system to the market in early 2013.

flow technologies

Farmers and crop producers across the globe face a myriad of challenges: increased input costs shrink profit margins, land values are at record highs, weather is unpredictable and markets are fluctuating. To earn a living, farmers rely on speed and accuracy when they plant, spray, and harvest their crops. Pentair Flow Technologies’ Hypro® precision agricultural solutions help farmers achieve this.

Hypro Agricultural Solutions

For Improved Farming The Hypro ExpressTM End Cap solves a costly and perplexing problem called “shut-off lag” – whereby crop spray chemicals continue to be sprayed through a boom even after the farmer shuts off the supply. This is caused by a buildup of trapped air in the boom, and leads to wasted chemicals, overspray, and delays in moving the boom to the next crop row. The Hypro Express End Cap solves this problem. Its channel allows air to automatically escape from the boom, reducing lag by as much as 85 percent, reducing wasted chemicals, lessening the environmental impact, and increasing efficiency. This makes farming more profitable.

Hypro ExpressTM Wet Boom Fittings allow crop protection equipment manufacturers to quickly and easily assemble their crop spray booms without special tools. Traditional systems can be complicated, time consuming, and expensive to assemble. Express Wet Boom Fittings solve this challenge through a unique, quick-connect system that instantly

aligns and locks boom pipe sections. The system eliminates the need for leak-prone threaded joints and expensive welded fittings, while also enabling the use of lighter stainless steel pipe, reducing material cost by as much as 50 percent. Reduced material costs and chemical leakage help farmers improve profitability. The Hypro Cleanload™ chemical eduction system enables farmers to mix liquid and dry chemicals safely and quickly at ground level. Traditional systems require climbing on and around equipment to haul expensive and dangerous chemicals to the top of the tank. This can lead to slips, falls, chemical spills, and mixing mistakes. The Cleanload utilizes a single, easily accessible hopper and mixing system to maximize farmer safety while minimizing costly chemical spills and mixing mistakes. Cleanload also has a built-in, self-cleaning system that can triple rinse chemical containers on-site and ready them for safe environmental

MIKE BOTHWELL

container disposal. The net result? More efficiency, less waste, improved safety and higher profit margins. Hypro’s newest spray tip, GuardianAIR Twin™, incorporates both a twin-spray design and air-inclusion droplets ideal for high-coverage application of post-emergent plant health protectants. The GuardianAIR Twin’s 30° forward and rear-facing fans help penetrate complex canopies that require more thorough coverage. This unique spray tip produces the same medium droplet size over an extended pressure range. This extended pressure range allows farmers, growers, and applicators to spray their fields at speeds that meet their needs. By listening to the needs and challenges of farmers across the globe, Pentair’s Flow Technologies is uniquely positioned to develop solutions to improve their precision, speed, and profitability. Look for more ground-breaking agricultural products throughout the year.

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a q u at i c s y s t e m s

Crystal Clear Water Conveniently by

JOSÉ GUILLEN

Sand filters are very easy to maintain, requiring pool owners to only turn a backwash valve. Filtration capabilities of sand filters, however, cannot compete with cartridges or D.E. filters, the other major types of home pool filters. To close this gap, Pentair developed the ClearPro Technology®, one of the best sand filtration in the market. ClearPro Technology®

The innovation lies in the patented component positioned inside the filter: a porous tube, permeable enough for water to be able to cross through without pressure loss but capable of acting as an efficient barrier against fine particles, such as dust, algae and pollen.

D.E. Filter Clarity with Sand Filter Functionality

Pentair sand filters with ClearPro Technology reach a very fine level of filtration; four times better than conventional sand filtration (about 10μ vs 40μ). That allows people who want to do the least work possible with their pool filter, to have results close to the best D.E. filters. That’s something no other sand filter is able to offer.

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A pool filter’s effectiveness is easily classified by the size of particles it can filter. Particles are measured in microns. For example, the average grain of beach sand is approximately 1.000 microns, a grain of salt is 90 to 110 microns and particles under 35 microns can’t be seen with the naked eye.

Slower is Better

The combination of ClearPro filters with Pentair’s variable speed pumps IntelliFlo® provides additional savings to the pool owner. Rick Chafey, from Red Rock Pools (US), explains, “When you run the pump longer and slower, you save energy. Longer, slower filter cycles negate friction and head loss, so you get better filtration with slower

Triton® II Sand Filter showing the laterals with ClearPro Technology ®.

flowing water.” Chafey compares this phenomenon to removing dirt from a T-shirt with a fire hose versus a sink faucet. A fire hose pushes dirt into and through the shirt, ruining it. On the other hand, holding a dirt-covered shirt under a sink faucet allows the dirt to rinse off the surface. High pressure, high velocity water can force dirt into and through the media, rather than allowing it to be caught (i.e. filtered) by the media. When dirt becomes embedded, it is difficult to remove.

Additional Advantages with Eco Select™ Products

Other efficiency-motivated selections are large-diameter plumbing and a high-end automation system such as the IntelliTouch® and IntelliPool®. All these automation systems, as well as the IntelliFlo pump, have been awarded with the Eco Select™ brand because of its capabilities to save energy and water, eliminate noise and innovations as environmentally sustainable equipment.

a q u at i c s y s t e m s

JOSÉ GUILLEN

Robotic cleaners offer consumers many benefits, namely convenience. It’s no wonder robotics are the fastest growing segment of cleaners. Dealers everywhere have taken notice and made robotics a vital part of conversations with customers who are looking for the latest innovations and technology for tough cleaning jobs.

Pentair Puts Robotic Cleaners on the Prowl

Features include: • Easy maintenance: filter cartridge is quick and simple to clean. • Ability to vacuums all types of debris and help remove algae. • Full cartridge indicator to indicate when Prowler needs attending. • Superior swivel design to help prevent cable tangling. • Auto-reverse to help prevent hang-ups near steps, corners and ladders.

Environmentally Responsible

As part of the Eco Select™ brand, the Kreepy Krauly Prowler 820 and 830 robotic cleaners are among Pentair’s most eco-friendly and energy-efficient equipment choices. Their internal filtration systems clean water as they circulate chemicals more thoroughly throughout the pool—reducing the need for chemicals and increasing water clarity. Their low-voltage operation reduces energy use—cleaning most pools for as little as 15 cents per cleaning, all without sacrificing cleaning performance.

This year, Pentair introduced its most advanced robotic cleaners to date— the Kreepy Krauly ® Prowler ® 820 and 830. These latest additions provide powerful cleaning with the hassle-free convenience customers expect from today’s pool cleaners.

The Ultimate in Performance and Convenience

The Prowlers’ superior engineering offers unmatched cleaning power and convenience. Its advanced design scrubs, vacuums and filters in just three hours, keeping pools spotless and inviting. Totally independent of pool circulation systems, the Prowler 820 and 830 allow

A Cleaner for Every Customer and Every Pool

for easy plug-and-play cleaning. No installation, costly-to-operate booster pump, or cumbersome hoses are required. Just plug it in, and place it in your pool. The Prowler does the rest.

The broad collection of powerful cleaners in the Kreepy Krauly family has led to more than three million sales worldwide. The products’ quality has made the Prowlers the most trusted brand of pool cleaners.

Its cleaning abilities and other features will have customers lining up to put the Prowler to work on their pool.

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process technologies

DÉSIRÉE MÄUELER

Since introducing its biogas upgrading system to the market in 2010, Pentair Haffmans has experienced amazing success with this innovative technology. Biogas upgrading projects have been commissioned in several European countries including the Netherlands, Germany and France. In early 2013, the first Haffmans biogas upgrading plant in the UK will start operation. Haffmans was awarded a contract to supply a biogas upgrading system to Springhill Farms in Worcestershire, UK. When this installation is in operation, it will produce 1,630,000 m3 of biomethane per year. This is enough to supply one year of natural gas to 1,000 households and recover 4,200 tons of carbon dioxide (CO 2). This system will be the first in the UK to feed biomethane into the natural gas grid and at the same time recover the CO 2 by-product. The recovered CO 2 is stored in a buffer tank and used as natural fertilizer for tomato cultivation in the farms’ greenhouses. The system configuration allows for precise dosing of the CO 2 according a set timetable that assures optimal plant growth. Installation of the

500 Nm3/h Haffmans’ system is scheduled to begin at the end of the year, with commissioning in the first quarter of 2013. Biogas Nord AG, a leading global supplier of turn-key biogas solutions based in Germany, is building the biogas plant. “Biogas Nord,” said managing director Asnat Drouianov, “is continuously looking for innovative solutions that offer benefits for the customer and the environment. Haffmans fits our strategy well as this technology offers a very efficient use of resources and at the same time provides sustainability benefits.” In total, more than 5,000,000 m3 of biomethane have already been produced with Haffmans’ technology, which

Springhill FarmS to Install First Biogas Upgrading System Supplied to the UK The CO 2 recovered during the biogas upgrading process is stored in a buffer tank for use in a variety of applications including as gaseous fertilizer in greenhouses.

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outperforms conventional techniques by providing two additional advantages. Biogas primarily consists of a mixture of methane and CO 2 . Haffmans’ technique makes it possible to recover 100 percent of the methane, thus eliminating the environmentally harmful ‘methane slip’. In addition, the CO 2 by-product is recovered for use in a variety of applications, including greenhouse growing. Haffmans’ Managing Director, Olaf Müller, said, “this new biogas upgrading system in the United Kingdom reconfirms the market requirements for our biogas upgrading technology and is another important step towards delivering innovations in the renewable energy sector.”

Award-winning technology

Pentair Haffmans is pleased to announce that it has won the Dutch Process Innovation Award 2012 for its biogas upgrading technology. The award honors the most innovative and forward-looking products and solutions in the Dutch process industry. The winner is selected by a jury composed of representatives of the process industry, research institutions and the media. Haffmans won over the jury with its innovative combination of proven technologies towards a more efficient and sustainable biogas upgrading technique. Haffmans competed against 24 best in class projects.

process technologies

The Waste Challenge

Cleaning In Place (CIP)

anaerobic bioreactor where the organic

strength wastewaters

Solution for Industries Industrial waste streams often put pressure on business’s operating costs. The Memthane® anaerobic membrane bioreactor (AnMBR) offers new opportunities to efficiently produce biogas from wastewater streams for a wide range of industries, enabling them to lower discharge costs.

Influent is fed to the

Conditioning of high-

components are converted

Biogas

into energy-rich biogas.

Safety Flare

CIP Chemicals

NH3 Fe NaOH

CIP

Byproduct Storage

Heated CIP Tank

CIP

Mixed Anaerobic Reactor

Islands, Scotland.

Raw Waste Feed

Membrane Byproduct and Wastewater Feed

Pump

Feed Pump

After anaerobic treatment, the UF membrane unit separates the clean permeate from the biomass.

Heat Recovery

Biomass Discharge

Permeate Discharge

If required, several polishing techniques are available to further treat the suspended solids free effluent for reuse or recovery of nutrients, while the low COD permeate is often clean enough for direct discharge to sewer.

Biomass is returned to the bioreactor, while a small amount of biomass is removed from the system and discharged after dewatering.

JANNA DIRKS

Previously, anaerobic systems’ pre- and post-treatment requirements complicated the process, making it more expensive than aerobic treatment methods. With the integration of Pentair X-Flow’s ultrafiltration (UF) membranes into its Memthane® AnMBR, Veolia Biothane mitigates this experience.

Memthane Solution

The Memthane® system offers the best solution by providing cost-effective industrial wastewater stream processing with very high levels of COD (chemical oxygen demand). Its ability to treat high-strength and high-solid wastes makes the Memthane® process especially suitable for use in distilleries, dairy industries, instant-coffee plants and bioethanol plants. This small footprint solution simplifies pre-treatment, anaerobic treatment and post-treatment, into a combined single ‘reactor-membrane’ unit. In the

Memthane® design, the influent is fed to the anaerobic bioreactor where the organic components are converted into energy-rich biogas. After this step, the reactor content is processed with X-Flow’s ultrafiltration (UF) membrane unit that separates the anaerobic sludge for returning to the reactor and provides a particle-free, clear effluent. The fully enclosed UF membranes are placed outside the reactor, making it a clean and easy to maintain solution that prevents odor release. Also, no biogas scouring is required with this membrane system.

Smart and Feasible Alternative

The Memthane® system offers the ideal alternative to reclaim energy from wastewater streams, converting almost all organic components into biogas, methane and carbon dioxide (CO 2). The Memthane® system removes 99 percent of incoming COD, compared to 80 to 85 percent in traditional anaerobic treatment

methods. This produces a higher biogas yield than in any other comparable process. The high waste-to-energy ratio also results in a significantly smaller plant design. Overall, substantial energy savings can be realized, and the produced biogas can cover a large portion or even the entire heat and energy demand of the production facility. Wastewater discharge costs can also be reduced because of the effluent’s purity that can be discharged directly to the sewer or upgraded for reuse. Combined, these advantages result in a return on investment period of, on average, less than two years.

KEY FEATURES AND BENEFITS

• High efficiency of 99% COD removal • Small footprint • Reduced sludge disposal costs • Easy operation & maintenance • Low cleaning frequency

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Biogas

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